Active support for industrial robots

Abstract

The invention relates to active support of an industrial robot. A system and method for automated support of an industrial robot. The system includes a data collection device that communicates with all robots at the customer site and uploads data to a remote diagnostic system. The method is activated automatically in the event of an alert, or by a robotic operator or a remote support team. Once activated, a particular diagnostic file is captured and sent from a controller of the affected robot to a data collection device and then to a remote diagnostic system. The system utilizes a knowledge base to diagnose the cause of the problem from the diagnostic file, and supports team personnel to participate therein to derive the diagnosis. Based on the diagnosis, updated software or profiles are sent to the affected robot to correct the problem and allow the robot to be put into use again, allow instructions to be provided to the robot operator, or allow a field service technician to plan access.

Description

Technical Field

[0001] This disclosure relates to the field of support services for industrial robots, and more specifically, to systems and methods for providing automated support for industrial robots, which are activated when a problem is detected, establish communication between a remote support system and a robot controller at the user's site, send diagnostic files from the affected robot controller to the remote support system, diagnose the cause of the problem, and send correction data and / or instructions from the remote support system to the affected robot. Background Technology

[0002] The use of industrial robots for a wide range of manufacturing, assembly, and material handling operations is well-known, and modern manufacturing facilities frequently employ various robots to automate production processes. Robots offer significant advantages over human labor in many factory operations, including speed and reliability of task execution, the ability to work in hazardous environments such as paint booths, and the capacity to repeatedly handle and move heavy objects. However, industrial robots are not without their problems. Like any machine, robots are susceptible to a variety of issues that affect their operation, known as malfunctions, errors, failure modes, etc. These problems can arise in the software running on the robot's controller or can affect the robot's mechanical components (such as bearings) or electronic components (such as articulated motors).

[0003] When a robot malfunctions, in many cases, the problem necessitates its shutdown. Therefore, diagnosing and correcting the problem as quickly as possible is crucial to minimizing downtime and production losses. This is especially true given that when one robot stops working, it can adversely affect many other devices. For example, on a continuous stamping production line, there is a series of stamping presses and auxiliary robots; if one auxiliary robot stops working, the entire stamping production line will shut down until that robot is repaired and put back into service.

[0004] Various methods have been used to try to minimize robot downtime. Many robot customers take proactive measures that monitor numerous parameters of robots operating in the factory and use data analytics and prediction to identify potential problem situations before failures occur. These technologies are effective because they allow for the inspection, maintenance, and / or replacement of robot components during regular preventative maintenance activities, thereby reducing the number of unexpected problems that occur during production operations. However, despite these proactive measures, robots can still encounter problems that lead to downtime.

[0005] When a problem occurs during robot operation, an alarm is activated on the robot controller, indicating the nature and severity of the warning or error. In some cases, the robot operator can perform simple maintenance or repairs and put the robot back into service. However, in many cases, the robot operator lacks the knowledge or experience to understand the details of the alarm codes or perform the necessary repairs to correct the underlying problem. In these situations, the operator must contact the robot manufacturer's service center and request service assistance.

[0006] It is known that a robot manufacturer's service center has a network connection to a server device at the customer's site, which in turn communicates with all robot controllers in the field. This communication network allows data files to be transferred from the affected robot's controller to a service center technician, who can then attempt to resolve the problem. However, the existing method requires the service center technician to explain to the robot operator which data files need to be located, and the operator must then manually email these files to the remote technician. This process sometimes occurs two or three times as the technician identifies the need for additional data. Furthermore, if the controller is restarted, critical data regarding the robot's status at the moment the problem occurred may be permanently lost.

[0007] In view of the above, there is a need for an improved system and method to provide automated support for industrial robots, which can quickly and reliably diagnose and repair robot problems. Summary of the Invention

[0008] Based on the teachings of this disclosure, a system and method for automated support of industrial robots are provided. The system includes a data collection device that communicates with all robots at the customer's site and uploads data to a remote diagnostic system. The method can be activated automatically when a problem is detected, by a robot operator displaying an alarm on the robot controller, or by a remote support team. Once activated, a specific diagnostic file is captured and sent from the affected robot's controller to the data collection device and then to the remote diagnostic system. The system utilizes a knowledge base to attempt to diagnose the cause of the problem from the diagnostic file, with support team members also involved in arriving at a diagnosis. Based on this diagnosis, updated software or configuration files are sent to the affected robot to correct the problem and allow the robot to be put back into service, instructions to the robot operator can be provided, and / or visits by on-site repair technicians can be scheduled if more complex repairs are required.

[0009] Other features of the systems and methods involved in this disclosure will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings. Attached Figure Description

[0010] Figure 1 This is a schematic diagram of a system in a first mode according to an embodiment of the present disclosure, the system being used to provide automation support for industrial robots at a customer site by personnel at a remote support center, in which the operator manually activates the support system;

[0011] Figure 2 It is a second mode of implementation according to the present disclosure for use Figure 1 The diagram shows an automated support system for an industrial robot, in which the robot controller automatically activates the system in this second mode.

[0012] Figure 3 It is a third mode of implementation according to the present disclosure for use Figure 1 The diagram shows an automated support system for an industrial robot, in which a remote support center activates the system in this third mode; and

[0013] Figure 4 This is a flowchart illustrating a method for providing active support for an industrial robot according to an embodiment of the present disclosure. Detailed Implementation

[0014] The following discussion of embodiments of the present disclosure for systems and methods for providing automation support for industrial robots is exemplary in nature and is not intended to limit the disclosed apparatus and technology, or their application and use.

[0015] Industrial robots are widely used in various manufacturing, assembly, and material handling operations. The use of industrial robots for a wide range of manufacturing, assembly, and material handling operations is well-known, and modern manufacturing facilities frequently utilize various robots to automate production processes. However, like any type of machine, robots are susceptible to various problems affecting their operation, including various malfunctions, errors, failure modes, etc. These problems can occur in almost any part of the robot system, including the software running on the robot controller, or any electronic or mechanical component or subsystem of the robot. After a problem or problem situation occurs, it is crucial for the robot operator to restore the robot to service as quickly as possible.

[0016] Various methods have been used to attempt to minimize robot downtime. Many robot customers take proactive measures that monitor numerous parameters of robots operating in their facilities and utilize data analytics and prediction to identify potential problem situations before failures occur. Such a system is disclosed in U.S. Patent Application Serial No. 14 / 951,557 (hereinafter referred to as "557 application"), which was subsequently granted U.S. Patent No. 10,616,080, and is jointly owned by the same patentee as this application, the entire contents of which are incorporated herein by reference. Techniques such as those in the aforementioned patent are effective because they enable the inspection, maintenance, and / or replacement of robot components during regular preventative maintenance activities, thereby reducing the number of unexpected problems occurring during production operations. However, despite these proactive measures, robots sometimes still encounter problem situations that lead to downtime.

[0017] When a problem occurs during robot operation, an alarm is activated on the robot controller, indicating the nature and severity of the warning or error. In most cases, when this happens, the operator must contact the robot manufacturer's support center and request service assistance. The support center may have a network connection to a server facility at the customer's site, enabling the transfer of data files from the affected robot's controller to support center technicians, who can then attempt to diagnose and resolve the problem. However, the current method requires support center technicians to explain to the robot operator which data files need to be located, and the operator must then manually locate the files and email them to the remote technician. This process can be slow and may need to be repeated, as technicians may identify other required data and are not always able to recover the critical files that captured the robot's state at the time of the malfunction.

[0018] This disclosure describes systems and methods for providing automated support for industrial robots, wherein the disclosed techniques overcome the shortcomings of existing remote robot support methods. The techniques of this disclosure automate and standardize the processes of capturing data from the controller of the affected robot, transmitting the data from the customer site to a centralized database, diagnosing problem situations, and sending instructions and corrective actions to the customer site.

[0019] Figure 1This is a schematic diagram of a system 100 used in a first mode according to an embodiment of the present disclosure, for providing automated support to industrial robots at a customer site by personnel from a remote support center. In the first mode, the support system is manually activated by the operator. The customer site 110 represents a factory or other facility where one or more robots are in operation. The term "customer" here refers to a company that purchases and operates the robots, which may be, for example, a product manufacturer or a food packaging company. Alternatively, a robot manufacturer sells and maintains the robots, including providing technical support in case of problems.

[0020] In this example, customer site 110 has a number of robots in operation, including at least robot 120 and robots 130-134. Robots 120 and 130-134 are merely examples of the many robots that may be present at customer site 110, where the robots may be of different types and models and can be configured to perform various operations, as shown in the different graphical representations. The robots at customer site 110 may include any combination of articulated robots and delta-type (parallel) robots. As shown in the graphical representations, each robot is understood to include a physical robot and a corresponding robot controller. Thus, robot 120 includes an articulated robot arm 122 and a robot controller 124.

[0021] Robots 120 and 130-134 communicate with a data collection device 140 located at customer site 110. In the accompanying drawings, the arrows from robots 130-134 to data collection device 140 are de-emphasized because they are irrelevant to the subsequent discussion; the active support methods of this disclosure are entirely described using examples involving robot 120. Data collection device 140 is a computer or server with data storage and processing capabilities, connected to all robots at customer site 110 via a local area network connection (wired or wireless), and possessing internet connectivity. Data collection device 140 may be part of an existing system in which it periodically receives operating parameter data from the controllers of each robot 120 and 130-134 and analyzes the operating parameter data to monitor the health status of the robots during normal operation. According to the techniques of this disclosure further discussed below, data collection device 140 may also receive specific data files from the individual robots at site 110 in the event of a problem.

[0022] Operator 150 at site 110 is responsible for operating the robot and may need to perform certain tasks, as discussed below, in the event of a problem. Support team 160 consists of a group of technical experts from the robot manufacturer who can assist in diagnosing and resolving any issues that arise. Support team 160 is located away from customer site 110. Members of support team 160 may be located in a single location, multiple locations, or dispersed across various locations. It is important to understand that they are technical experts with access to data from customer site 110 to help resolve any robot problems that may occur.

[0023] Data files from data collection device 140 can be automatically uploaded to diagnostic system 180 via cloud (Internet) connection 170. Diagnostic system 180 is a globally accessible server / computer, including a database, software for performing analysis, diagnostics, and communication, and a user interface. In one example, the database in diagnostic system 180 is configured to manage data for individual customer sites. That is, the operator 150 at customer site 110 can easily access and view data at his / her site, but cannot access data at other sites, and members of support team 160 can easily select all data and files from site 110 for viewing and analysis via the user interface of diagnostic system 180.

[0024] right Figure 1 The preceding discussion described the people, devices, and connections included in system 100. Next, we will discuss how system 100 is used in a first mode, where operator 150 manually activates the support system. The following discussion will cover… Figure 2 and Figure 3 Other activation and operation modes of system 100 are shown.

[0025] Figure 1 The manual activation technique illustrated begins when operator 150 determines that a robot at customer site 110 is experiencing a problem. In this example, the problem or issue concerns robot 120. This problem may be identified via an alarm (audible, visual, electronic notification, or any combination thereof) from robot 120's controller 124. Upon learning of the problem with robot 120, operator 150 contacts support team 160 (indicated by the arrow labeled step ①) and describes the alarm, error, or problem situation occurring with robot 120. Contact can be made in any suitable manner, including telephone calls, email, regular text messages, or dedicated messaging services available as part of a proactive support approach. These various forms of communication also apply to any and all subsequent communications between operator 150 and support team 160. The arrow for step ① is shown bidirectionally because support team 160 subsequently provides operator 150 with instructions for the next steps.

[0026] In step ②, operator 150 activates an active support method for robot 120 according to instructions from support team 160. This activation can be physically performed on robot 120's controller 124 using a "teach pendant" device communicating with controller 124, or via a user interface capable of monitoring and controlling all robots at customer site 110. Upon activation of the active support method, robot 120 sends a message to data collection device 140 indicating the need for diagnostic documentation (step ③). The message from robot 120 to data collection device 140 preferably indicates the exact type (such as a code) of the error, malfunction, or alarm that has occurred, which in turn indicates which specific diagnostic documentation is required. Diagnostic documentation may include: log files with historical data, debug files, and any other files containing data about robot 120's operation that aid in diagnosing the problem situation. It is understood that, for example, the diagnostic documentation required for a collision detection alarm (in this case, a collision between parts of robot 122 and another object) will be significantly different from that required for a joint motor malfunction or controller operating system error.

[0027] In step ④, the data collection device 140 communicates with the robot 120 and retrieves (transmits) the required diagnostic files from the robot 120's controller 124. The data collection device 140 may copy diagnostic files already existing on the robot 120's controller 124, and the data collection device 140 may also execute commands on the controller 124 to generate additional debug or log files required as part of the diagnostic files.

[0028] As described above, in some embodiments of system 100, data collection device 140 periodically receives operational parameter data from the controllers of each robot 120 and 130-134. This operational parameter data is received even when the robots are operating normally, without problems or errors. The operational parameter data is analyzed in data collection device 140 and / or in diagnostic system 180 to identify preventative maintenance that may be required for any robot. For example, the operational parameter data may indicate that a particular joint in robot 132 has reached the end of its service life (in terms of cumulative rotation angles, load cycles, etc.) and that the joint should be maintained or replaced. This continuous robot diagnostic activity is disclosed in the previously mentioned "557 application" and is independent of the proactive support methods disclosed herein.

[0029] In step ⑤, the data collection device 140 sends the diagnostic files (related to errors on robot 120) to the diagnostic system 180 via the cloud 170. The diagnostic files are stored in the database of the diagnostic system 180, and when the upload / storage process is complete, the diagnostic system 180 indicates in step ⑥ that the data is ready for access via the user interface. In step ⑦, both the support team 160 and the operator 150 are able to access and download the captured diagnostic data files related to problems or errors on robot 120.

[0030] In some cases, operator 150 may possess sufficient knowledge and experience to diagnose and resolve the problem independently based on a review of captured diagnostic data files related to errors on robot 120. In these situations, the proactive support method of this disclosure offers the benefit of streamlining and accelerating the diagnostic process by automatically capturing diagnostic files and presenting them to operator 150. Operator 150 simply activates the proactive support method for robot 120 and then, after a short period, accesses the diagnostic files from diagnostic system 180. Using previous / existing methods, operator 150 would have had to consult with support team 160 to determine which diagnostic files were needed for a specific error or problem on robot 120, and how to find, copy, or create the required files. Operator 150 would then have had to analyze the diagnostic files themselves and would likely also need to email the diagnostic files to support team 160.

[0031] When support team 160 accesses a captured diagnostic data file related to an error in robot 120, this may include automated diagnostics performed by diagnostic system 180. For example, diagnostic system 180 may determine that the diagnostic data matches a known problem that has been resolved in a later version of a software module or configuration file of the operating system. When support team 160 accesses diagnostic system 180, the diagnostics will be displayed in the user interface.

[0032] If the diagnostic system 180 fails to provide a diagnosis of the problem based on the diagnostic data, the support team 160 will attempt to diagnose the problem using their own knowledge and experience, knowledge databases, and all available data.

[0033] Once the problem diagnosis is complete, whether through analytical diagnosis by support team 160 or automated diagnosis by diagnostic system 180, support team 160 will provide the problem diagnosis and possible solutions in step ⑧. Communication between support team 160 and operator 150 in step ⑧ can take many different forms. For example, in the event of a robot collision alarm, support team 160 might instruct operator 150 to check the area around robot 120 to ensure that all robot operating areas and safety areas are free of foreign objects. In the event of a mechanical or electronic failure of a component on robot 120, support team 160 might notify operator 150 that a field repair technician has been arranged to repair or replace the affected component. In other cases, support team 160 might instruct operator 150, under its guidance or using an augmented reality maintenance system, to perform relatively simple repair tasks. Many other types of communication may also occur between support team 160 and operator 150 in step ⑧, including various forms of instructions, status updates, and action commands to be performed by operator 150.

[0034] In step ⑧, in addition to informing operator 150 of the actions taken, communication by support team 160 may also include taking direct action to resolve the issue. This is indicated by the branch of the arrow pointing to data collection device 140 in step ⑧. For example, when diagnostics indicate that the problem lies in a software module or configuration file of the operating system, and a subsequent version has resolved it, support team 160 can copy the appropriate file to data collection device 140, which in turn copies the file to controller 124 of robot 120. Subsequently, data collection device 140 may command controller 124 to perform an automatic restart, at which point operator 150 will be notified that robot 120 is ready to be put back into service. This proactive support from start to finish provides significant value to robot operators (customers), where operator 150 only needs to trigger the proactive support approach to begin, and all data retrieval / transmission, diagnostic, and resolution steps are performed automatically.

[0035] Even if a clear diagnosis of the problem cannot be made, the support team 160 will still communicate with the operator 150 in step ⑧ to recommend and discuss other corrective measures that can be taken.

[0036] Figure 2 It is used in a second mode according to an embodiment of this disclosure for Figure 1 The diagram shows an automated support system 100 for an industrial robot. In the second mode, the robot controller automatically activates the system. Figure 2 In the automatic activation mode, the active support method is activated if the operator 150 does not take any action.

[0037] Figure 2 The automatic activation technology shown begins when the controller 124 determines that a problem exists with the robot 120. The operator 150 may also become aware of the problem due to an alarm. To activate the proactive support method, the robot 120 sends a message to the data collection device 140 indicating that a problem has been detected and diagnostic documentation is required (step ①). The message from the robot 120 to the data collection device 140 should ideally indicate the exact type of error, fault, or alarm (by identifying error or fault codes), and thus indicate which specific diagnostic documentation is needed. As described above regarding... Figure 1 The diagnostic files discussed may include: log files with historical data, debug files, and any other files containing data about the operation of robot 120 that help diagnose problem situations.

[0038] In step ②, the data collection device 140 communicates with the robot 120 and retrieves (transmits) the required diagnostic files from the robot 120's controller 124. The data collection device 140 may copy diagnostic files already existing on the robot 120's controller 124, and the data collection device 140 may also execute commands on the controller 124 to generate additional debug or log files required as diagnostic files.

[0039] In step ③, the data collection device 140 sends the diagnostic files (related to the errors on robot 120) to the diagnostic system 180 via the cloud 170. The diagnostic files are stored in the database of the diagnostic system 180, and when the upload / storage process is complete, the diagnostic system 180 instructs in step ④ that the data is ready for access via the user interface. In step ⑤, both the support team 160 and the operator 150 are able to access and download the captured diagnostic data files related to the errors on robot 120. Notification of the data file's availability is provided to the support team 160 and the operator 150 via email or other means such as instant messaging.

[0040] The remaining issues, including diagnosis, communication, and resolution (step ⑥), are discussed in... Figure 2 (Automatic activation) in Figure 1 The same applies to (manual activation). This includes diagnosing the problem situation by the diagnostic system 180 and / or support team 160, communicating the diagnosis to operator 150 by support team 160, taking action by operator 150 to resolve the problem situation, and, where possible, taking action by support team 160 to resolve the problem situation on robot 120 by sending documents and / or commands to data collection device 140 (e.g., installing a new version of the configuration file and restarting the controller). The diagnosis and resolution of the problem situation may also include operator 150 diagnosing and resolving the problem situation based on his / her review of the diagnostic documentation.

[0041] Figure 2 The automated activation of the proactive support approach shown provides customers with an even faster and easier support solution. In some cases, the problem situation is resolved, and the robot resumes proactive service without any action taken by operator 150, who simply learns what happened in steps ⑤ and ⑥. Even when the problem situation cannot be fully resolved, such as when robot parts need to be replaced by a service technician during a field visit, the proactive support approach remains quick and simple for operator 150 because there is no need to seek instructions from support team 160 regarding the required diagnostic documents, nor is there a need to identify the diagnostic documents and email them to support team 160.

[0042] Figure 3 This is a method for use in a third mode according to embodiments of the present disclosure. Figure 1 The diagram shows an automated support system 100 for an industrial robot. In the third mode, a remote support team 160 activates the system. Similarly, in... Figure 3 In the remote activation mode, the active support method is initiated if the operator 150 does not take any action.

[0043] Figure 3 The automatic activation technology illustrated begins when the support team 160, monitoring operational data through the diagnostic system 180, discovers a problem with a specific robot (robot 120 in this example) (step ①). As previously described, the diagnostic system 180 periodically receives robot operational parameter data from the customer site 110, and includes algorithms for analyzing the data to identify parameters that are outside their normal range or exhibit abnormal trends. Therefore, by periodically monitoring the diagnostic system 180, the support team 160 can identify robot problems before the operator 150 identifies the problem or the robot controller itself triggers an alarm.

[0044] In step ②, support team 160 notifies operator 150 that a problem or potential problem situation has been identified on robot 120, and also requests appropriate diagnostic documents from data collection device 140. As previously discussed, diagnostic documents may include log files with historical data, debug files, and any other files containing data about the operation of robot 120 that can help diagnose the problem situation. In step ③, data collection device 140 communicates with robot 120 to indicate that certain diagnostic documents are needed, and in step ④, the required diagnostic documents are transmitted from controller 124 to data collection device 140.

[0045] In step ⑤, the data collection device 140 sends the diagnostic file to the diagnostic system 180 via the cloud 170. The diagnostic file is stored in the database of the diagnostic system 180, and when the upload / storage process is complete, the diagnostic system 180 indicates in step ⑥ that the data is ready for access via the user interface. In step ⑦, both the support team 160 and the operator 150 are able to access and download the captured diagnostic data file related to the problem or error of the robot 120. In step ⑦, a notification that the data file is available is provided to the support team 160 and the operator 150 via email or other means such as instant messaging.

[0046] The remaining issues or problem situations, including diagnosis, communication, and resolution (step ⑧), are discussed in... Figure 3 (Supports team activation) in and in Figure 1 (Manual activation) and Figure 2 The same applies to (automatic activation). This includes diagnosing the problem situation by the diagnostic system 180 and / or support team 160, communicating the diagnosis to operator 150 by support team 160, taking action by operator 150 to resolve the problem situation where possible, and taking action by support team 160, where possible, to resolve the problem or problem situation by sending documents and / or commands (e.g., installing a new version of the configuration file and restarting the controller) to data collection device 140 for implementation on robot 120. The diagnosis and resolution of the problem situation may also include operator 150 diagnosing and resolving the problem situation based on his / her review of the diagnostic documents.

[0047] Figure 3 The proactive support approach illustrated provides the support team with another quick and easy support solution for customers. In some cases, the problem situation is resolved, and the robot returns to proactive service without any action taken by operator 150, who simply learns what is happening in steps ②, ⑦, and ⑧. Even when the problem situation cannot be fully resolved, such as when robot parts need to be replaced by service technicians during an on-site visit, the proactive support approach is faster and easier than existing methods that require operator 150 to identify, copy diagnostic documents, and send them to support team 160 via email.

[0048] Figure 4 This is a flowchart 400 illustrating a method for providing active support for an industrial robot according to an embodiment of the present disclosure. Figure 4 The method is to use Figures 1 to 3The system 100 shown implements this. At box 402, the proactive support method is activated when a problem or problem situation is identified with the robot at the customer site. This problem or problem situation can be identified by the robot operator at the customer site, the robot's own controller, or a support team from the robot manufacturer located remotely from the customer site. At box 404, diagnostic documents related to the robot's problem situation are identified and transmitted from the robot controller to a data collection device at the customer site. The diagnostic documents can be identified and transmitted to the data collection device by the support team, or the documents can be identified by the data collection device itself based on error or alarm codes provided by the robot controller.

[0049] At box 406, the diagnostic files are transferred from the customer's field data collection device to a database that is part of the cloud-based diagnostic system. At box 408, the diagnostic system notifies the support team and robot operator that the diagnostic files are available for viewing and download. At box 410, robot problems are diagnosed. This may include the robot operator or support team diagnosing the problem after reviewing the diagnostic files, or it may include the diagnostic system diagnosing the problem after analyzing the diagnostic files.

[0050] At box 412, the support team communicates the problem diagnosis to the robot operator and, where possible, sends files and / or commands to the robot controller via data collection devices to resolve the issue. Problem resolution may also involve the robot operator performing repair tasks or taking other actions on the affected robot or its controller based on their own diagnosis or the support team's communication. In some cases, problem resolution can only be accomplished by a trained service technician via on-site visit; in such cases, the service technician's visit is arranged by the support team.

[0051] Throughout the preceding discussion, various computers and controllers have been described and implied. It should be understood that the software applications and modules of these computers and controllers execute on one or more computing devices having processors and memory modules. Specifically, this includes processors in each of the controllers of robots 120 and 130-134, the data collection device 140, and the diagnostic system 180. Specifically, the processors in these devices are configured, in a manner consistent with the foregoing disclosure, to identify problems with the robot, determine which diagnostic documents are needed to assist in diagnosing the problems, transmit the required diagnostic documents to the data collection device and the cloud-based diagnostic system, and analyze and communicate the data and diagnostics.

[0052] As described above, the disclosed technology for providing automated support for industrial robots offers significant advantages over existing methods. Using the disclosed proactive support system and methods, all necessary diagnostic documentation is captured upon the occurrence of an alarm or malfunction. This documentation is then automatically uploaded from the customer site to a cloud-based diagnostic system for access by a team of trained support personnel. There is no need for inexperienced robot operators to attempt to find the required diagnostic documentation and then manually email it to a member of the support team. This enables faster and more reliable diagnosis of robot problems, quicker problem resolution, and faster return to service of the robot.

[0053] While several exemplary aspects and implementations of systems and methods for providing automation support for industrial robots have been discussed above, those skilled in the art will recognize modifications, arrangements, additions, and sub-combinations therein. Therefore, it is intended that the appended claims and the claims described herein be understood to include all such modifications, arrangements, additions, and sub-combinations within their true spirit and scope.

Claims

1. A method for providing active support to an industrial robot, the method comprising: It was determined that the robot at the facility encountered a problem that needed to be solved. Identify one or more diagnostic documents required to diagnose the problem; The diagnostic file is transmitted from the robot's controller to the data collection device located at the facility; The data collection device uploads the diagnostic files to a cloud-based diagnostic system located remotely from the facility; The diagnostic system notifies the robot operator at the facility and the support team located far from the facility that the diagnostic documents are available. A diagnosis of the problem is determined based on the diagnostic document; and The problem is resolved based on the diagnosis.

2. The method according to claim 1, wherein, Once the robot operator determines that the robot has encountered a problem, the robot operator then notifies the support team of the problem.

3. The method according to claim 1, wherein, The robot's controller determines that the robot has encountered a problem, and then notifies the data collection device of an alarm or error code.

4. The method according to claim 1, wherein, Once the support team determines that the robot has encountered a problem, the support team will then communicate the information about the problem to both the robot operator and the data collection device.

5. The method according to claim 1, wherein, The robot's controller or the data collection device identifies one or more diagnostic files based on alarms or error codes.

6. The method according to claim 1, wherein, The support team identifies one or more diagnostic files.

7. The method according to claim 1, wherein, The diagnostic system determines the diagnosis of the problem by comparing the diagnostic file with files stored in a knowledge base of previous robot problems and diagnoses.

8. The method according to claim 1, wherein, The support team determines the diagnosis of the problem.

9. The method according to claim 1, wherein, The diagnosis of the problem is determined by the robot operator.

10. The method according to claim 1, wherein, Solving the problem based on the diagnosis includes: the robot operator or service technician performing actions on the robot or the controller.

11. The method according to claim 1, wherein, Solving the problem based on the diagnosis includes the support team electronically sending one or more of the following to the robot's controller: software files, configuration files, and command instructions.

12. The method according to claim 1, wherein, The diagnostic files include one or more of the following: log files with historical data, debug files, backup files, software programs and configuration files, and files containing data about the robot at the time the problem occurred.

13. The method according to claim 1, wherein, The problems to be solved include: faults or errors in the hardware or software of the controller, robot collision alarms, or problems with any mechanical or electronic components or subsystems of the robot.

14. The method according to claim 1, wherein, The robot's controller and the data collection device are computing devices with processors and memory, and the diagnostic system includes a computing device, a database, diagnostic software, and a user interface.

15. The method according to claim 1, wherein, The robot is one of a plurality of robots operating at the facility, and other data collection devices at other facilities also communicate with the diagnostic system.

16. A method for providing active support to an industrial robot, the method comprising: The robot's controller determines that the robot has encountered a problem that needs to be solved; Identify the diagnostic documents required to diagnose the problem; One or more diagnostic files are transmitted from the robot's controller to the data collection device located at the facility along with the robot, wherein the diagnostic files required to diagnose the problem are identified by the controller or the data collection device based on an alarm code that identifies the problem; The data collection device uploads the diagnostic files to a cloud-based diagnostic system located remotely from the facility; The diagnostic system notifies the robot operator at the facility and the support team located far from the facility that the diagnostic documents are available. A diagnosis of the problem is determined based on the diagnostic document; and The problem is resolved based on the diagnosis.

17. The method according to claim 16, wherein, The diagnostic system determines the diagnosis of the problem by comparing the diagnostic file with files stored in a knowledge base of previous robot problems and diagnoses, and resolves the problem based on the diagnosis by having the support team electronically send one or more of software files, configuration files, and command instructions to the robot's controller.

18. A system for providing active support to an industrial robot, the system comprising: Multiple robots and controllers operating at the facility; A data collection device, having a processor and memory, is located at the facility and communicates with the controller; as well as The diagnostic system, comprising a processor and memory, a database, diagnostic software, and a user interface, is located remotely from the facility and accessible via an internet connection. When a problem is identified in a particular robot, one or more diagnostic files are identified as needed to diagnose the problem. These diagnostic files are automatically transmitted from the controller of the particular robot to the data collection device and uploaded by the data collection device to the diagnostic system. The diagnostic system then notifies the robot operator at the facility and the support team located far from the facility that the diagnostic files are available. Based on the diagnostic files, a diagnosis of the problem is determined, and the problem is resolved based on the diagnosis.

19. The system according to claim 18, wherein, The diagnostic files include one or more of the following: log files with historical data, debug files, backup files, software programs and configuration files, and files containing data about the specific robot at the time the problem occurred.

20. The system according to claim 18, wherein, The problem with the specific robot is identified by the robot operator, who then notifies the support team; or by the controller of the specific robot, who then notifies the data collection device of an alarm or error code; or by the support team, who then conveys information about the problem to both the robot operator and the data collection device.

21. The system according to claim 18, wherein, The one or more diagnostic files are identified by the controller of the specific robot, the data collection device, or the support team based on alarms or error codes.

22. The system according to claim 18, wherein, The diagnostic system determines the diagnosis of the problem by comparing the diagnostic file with files stored in a knowledge base of previous robot problems and diagnoses, or by the support team or the robot operator.

23. The system according to claim 18, wherein, The problem is resolved by the robot operator or a service technician who performs actions on the particular robot or its controller, or by the support team electronically sending one or more of the software files, configuration files, and command instructions to the controller of the particular robot.

24. The system according to claim 18, wherein, The problems include: faults or errors in the hardware or software of the controller of the particular robot, robot collision alarms, or problems with any mechanical or electrical components or subsystems of the particular robot.

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